Method and apparatus (continuous imperforate portions on backing means of closed sandwich)

ABSTRACT

Method and apparatus for producing nonwoven fabrics that contain holes or other areas of low fiber density and have a plurality of patterns of groups of fiber segments that alternate and extend throughout the fabric. The method and apparatus include the steps of positioning the starting web between an apertured forming means and a backing means that has continuous imperforate portions that lie between and interconnect discontinuous foraminous portions, then directing fluid rearranging forces through the apertures of the forming means against the fibers of the starting web, causing some of the fluid streams to strike continuous imperforate portions of the backing means and all of the fluid streams ultimately to pass through the foraminous portions of the backing means.

United States Patent Kalwaites METHOD AND APPARATUS (CONTINUOUSIMPERFORATE PORTIONS ON BACKING MEANS OF CLOSED SANDWICH) Jan. 29, 19743,485,708 12/1969 Ballou et a]. 19/16l P X Primary ExaminerDorsey NewtonAttorney, Agent, or FirmRobert L. Minier 5 7] ABSTRACT Method andapparatus for producing nonwoven fabrics that contain holes or otherareas of low fiber density and have a plurality of patterns of groups offiber segments that alternate and extend throughout the fabric. Themethod and apparatus include the steps of positioning the starting webbetween an apertured forming means and a backing means that hascontinuous imperforate portions that lie between and interconnectdiscontinuous foraminous portions, then directing fluid rearrangingforces through the apertures of the forming means against the fibers ofthe starting web, causing some of the fluid streams to strike continuousimperforate portions of the backing means and all of the fluid streamsultimately to pass through the foraminous portions of the backing means.

4 Claims, 24 Drawing Figures PATENTED JAN 2 9 i872 SHEET 02 0F INVENTOR.fP/m A ATTORNEY.

PATENTED 29 I974 SHEET 03 0F INVENTOR fPA VA Mum/75s ATTORNEY.

PAIENTED JAN 2 91974 SHEET 0% OF OO/NQOOOOOOOOO INVENTOR fIW/VA A691.44/755 T K WJWM TTO R N EY PATENTED JAN 2 9 I974 SHEET 05 0F u ATTORNEY,

INVENTORI FRANK K14 11 4/7155.

BY V

ATTORNEY.

PAIENTEUJANZQISH SHEET 09 [1F INVENTOR. FRANK A714 IVA/7'55 ATTORNEYMETHOD AND APPARATUS (CONTINUOUS IMPERFORATE PORTIONS ON BACKING MEANSOF CLOSED SANDWICH) This is a continuation-in-part application of mycopending application Ser. No. 22,309, filed Mar. 24, 1970 nowabandoned.

This invention relates to a method and apparatus for the production ofnonwoven fabrics, and more particularly to a method and apparatus forthe production of non-woven fabrics from a layer of fibrous materialsuch as a fibrous web in which the individual fiber elements are capableof movement under the influence of applied fluid forces, to form afabric that contains apertures or holes, or other areas of low fiberdensity, and has a plurality of patterns of groups of fiber segmentsthat alternate and extend throughout the fabric.

BACKGROUND OF THE INVENTION Various methods and apparatus formanufacturing apertured nonwoven fabrics involving the rearrangement offibers in a starting layer of fibrous material have been known for anumber of years. Some of the methods and apparatus for the manufactureof such fabrics are shown and described in U.S. Pat. No. 2,862,251,which discloses the basic method and apparatus of which the presentinvention is a specific form, and in U.S. Pat. Nos. 3,081,500, 3,025,585and 3,033,721.

The nonwoven fabrics made by the methods and apparatus disclosed inthose patents contain apertures or holes, or other areas of low fiberdensity, often outlined by interconnected yarn-like bundles of closelyassociated and substantially parallel fiber segments. (The term areas oflow fiber density is used in this specification and claims to includeboth (1) areas in which relatively few fibers are found in comparison tothe rest of the fabric, and (2) apertures (holes) that are substantiallyor entirely free of fibers.)

One of the specific methods for producing rearranged nonwoven fabricsthat is disclosed in U.S. Pat. No. 2,862,251 is to support a loosefibrous web or layer between an apertured forming member and a permeablebacking member, and then direct streams of rearrangingfluid through theapertures of the former member in order to apply spaced sets of opposingfluid forces to the layer. The spaced streams of fluid pass through thefibrous layer and over and through the backing member, to pack groups offiber segments into closer proximity and substantial parallelism ininterconnected yam-like bundles of fiber segments that define holes orother areas of low fiber density corresponding to the pattern of theapertures in the apertured forming means.

Another known method for producing rearranged nonwoven fabrics is tosupport a loose fibrous web or layer upon solid backing means withspaced apertures distributed throughout the area thereof, and directstreams of rearranging fluid against the fibrous starting layer so thatthe fluid passes through that layer and then out through the spacedapertures in the backing means. The result of this method is to form anub of interentangled, tightly packed, helter-skelter fiber segments ineach aperture of the backing means, and to position other fiber segmentsin flat, ribbon-like groups of substantially aligned fiber segmentsbetween pairs of immediately adjacent nubs to interconnect the same.

In the first method just described, the streams of rear ranging fluidenter the fiber rearranging zone at spaced locations determined by theposition of the apertures in the apertured forming means against whichthe fluid streams are first directed. Then, when the rearranging fluidleaves the rearranging zone, it does so through foramina uniformlydispersed throughout the permeable backing member.

Exactly the contrary is true with the second method just described. Inthat method, the streams of rearranging fluid are dispersed uniformlyacross the layer of fibrous starting material as they are directedagainst that layer upon entering the rearranging zone, and leave therearranging zone at spaced locations determined by the position of theapertures in the apertured backing means.

Another significant feature of the second method is that streams ofrearranging fluid initially dispersed uniformly across the fibrousstarting layer are consolidated into spaced streams confined by thewalls of the apertures in the apertured backing means as they pass outof and away from the fiber rearranging zone. It is this consolidation ofthe streams of fluid that creates the turbulence that in turn packs thenubs in the nonwoven fabric of this prior art method into tightlycompacted, interentangled fiber accumulations, with the individualfibers thereof having entirely random orientation.

SUMMARY OF INVENTION I have now discovered that, unexpectedly, one cancombine these two different prior art methods of producing rearrangednonwoven fabrics, and achieve very satisfactory rearrangement of thefibers of the fibrous starting material into a fabric having a pluralityof patterns of groups of fiber segments that alternate and extendthroughout the fabric.

In the method of this invention, the starting material is a layer offibrous material whose individual fibers are in mechanical engagementwith one another but are capable of movement under applied fluid forces.The layer of fibrous starting material is supported in a fiberrearranging zone in which fiber movement in directions parallel to theplane of said fibrous material is permitted in response to applied fluidforces. Streams of rearranging fluid, preferably water, are projectedinto the fibrous layer at entry zones spaced from each other adjacentone surface of the layer. For ease of visual resolution of the patternson the resulting fabric, each of the entry zones has a width at itsnarrowest part equal to at least about ten times, and preferably abouttwenty or more times, the average diameter of the fibers of the fibrousstarting material. These streams of rearranging fluid are passed throughthe layer of fibrous starting material as it lies in the rearrangingzone, to effect movement of at least some segments of the fiberstransverse to the direction of travel of the projected streams.

In the next step of the method, the passage of first portions of therearranging fluid out of the fibrous layer is blocked at continuousbarrier zones located adjacent the opposite surface of the fibrouslayer, and, at the same time, those portions of fluid are deflectedsidewise towards the other portions of the rearranging fluid and areactively mingled with the latter. For ease of visual resolution of thevarious fiber patterns in the fabric resulting from use of thisinvention, each of the barrier zones has a width at its narrowest partequal to at least about the width of one of the entry zones at itsnarrowest part. All the portions of intermingled rearranging fluid arethen passed out of the rearranging zone through spaced, discontinuous,foraminous major fiber accumulating zones defined by the continuousbarrier zones and each having an area at least about three times, andpreferably about four or more times, the area of one of the entry zones.

The passage of the rearranging fluid through the layer of fibrousstarting material as just described moves some of the fiber segmentsthat are in registry with the continuous barrier zone into the majorfiber accumulating zones, and positions those fiber segments with otherfiber segments in at least one yarn-like bundle of closely associatedand substantially parallel fiber segments in each major fiberaccumulating zone in a location therein complementary to the entryzones. In addition, the rearranging fluid moves other fiber segmentsthat are in registry with the barrier zones into substantial alignmentin bridging positions extending between the discontinuous major fiberaccumulating zones.

The result of this fiber rearrangement is a nonwoven fabric having afirst pattern of groups of fiber segments in discontinuous portions ofthe fabric corresponding to the pattern of the major fiber accumulatingzones, each of the discontinuous portions of the fabric in this firstpattern including at least one yarn-like bundle of closely associatedand substantially parallel fiber segments. The fabric also includes asecond pattern of groups of substantially aligned fibers extendingbetween pairs of discontinuous portions of the fabric immediatelyadjacent each other in the first pattern. In some form of the invention,as explained below, third and fourth patterns of groups of fibersegments are also present.

In one form of the method and apparatus of this invention, the fibrousstarting layer is supported on a backing means that is imperforateexcept for spaced foraminous portions arranged in a discontinuouspattern, and an apertured forming means is positioned above the fibrouslayer to provide a zone in which fiber movement in directions parallelto the backing means can occur in response to applied fluid forces. Thewidth of each forming aperture at its narrowest part is equal to atleast about ten times, and preferably about twenty or more times, theaverage diameter of the fibers of the fibrous starting material. Thearea of each of the foraminous portions of the backing means is at leastabout three times, and preferably about four of more times, the area ofan aperture of the apertured forming means. The imperforate portions ofthe backing means lie between and interconnect the discontinuousforaminous portions.

With a layer of fibrous starting material positioned between theelements just described, streams of rearranging fluid, preferably water,are projected through the apertures of the apertured forming means,against the layer of fibrous starting maerial; against the continuousimperforate portions of the backing means, and out through thediscontinuous foraminous portions of the backing means. At thediscontinuous foraminous portions of the backing means, the portions ofthe rearranging fluid that have struck the imperforate portions of thebacking means, and have been deflected thereby, are actively mingledwith othe portions of rearranging fluid.

Under the forces applied by these streams of fluid, some of the fibersegments that are in registry with the continuous imperforate portionsof the backing means are moved into areas of the fibrous layer overlyingthe foraminous portions of the backing means, to form groups of fibersegments there that include at least one yarn-like bundle of closelyassociated and substantially parallel fiber segments in each such area,while other fiber segments in registry with the continuous imperforateportions of the backing means are moved into substantial alignment inpositions bridging those imperforate portions. In addition, whendesired, fiber segments that are in registry with the apertures of theapertured forming means and also with the foraminous portions of thebacking means may be moved by the rearranging fluid into surroundingareas of the fibrous layer, where they are positioned in yarn-likebundles of closely associated and substantially parallel fiber segments,to define holes or other areas of low fiber density.

The action of the rearranging fluid just described produces a nonwovenfabric having two or three fiber patterns, all of which alternate andextend throughout the fabric. The first pattern is a pattern of groupsof fiber segments arranged in accordance with the pattern of arrangementof the discontinuous foraminous portions of the backing means, each suchgroup containing at least one yarn-like bundle of fiber segments. Thesecond is a pattern of groups of substantially aligned fiber segmentsinterconnecting the portions of the fabric in the first pattern; thispattern corresponds to the configuration of the continuous imperforateportions of the backing means, and these groups of aligned, bridgingfiber segments may take the form of fiat ribbon-like groups, yarn-likebundles, or a latticework of yarn-like bundles. The third pattern, whenit is present, is an elaboration of bundles within the first pattern,and is a pattern of yarn-like bundles of closely associated andsubstantially parallel fiber segments, arranged in accordance with theland areas of the apertured forming means, that may define a pattern ofholes or other areas of low fiber density.

An interesting result is obtained with this invention when the startinglayer of fibrous material is not too heave in weight and the foraminousportions of the backing means have a plurality of protuberances andtroughs alternating across their surfaces in both the longitudinal andtransverse directions. The resulting fabric displays a fourth patternextending throughout the fabric, in addition to the three fiber patternsalready described. This fourth pattern, which is disposed within thethird pattern described, is a pattern of yarnlike bundles of closelyassociated and substantially parallel fiber segments arranged accordingto the pattern of the troughs on the backing means, and lying within theholes or other areas of low fiber density in the third pattern.

The interaction of the different types of rearranging forces in the twoprior art methods that have been described above would be expected toproduce highly undesirable results. In the present invention, thestreams of rearranging fluid entering the fiber rearranging zone atspaced locations such as the apertures of an apertured forming means(i.e., spaced entry zones) produce yarn-like bundles of fiber segmentsin the areas of the fibrous starting material in either or both of twolocations, depending upon a number of reaction conditions above thediscontinuous foraminous portions of the backing means (i.e., fiberaccumulating zones) and above the continuous interconnecting imperforateportions of the backing means (i.e., barrier zones). In either case,undesirable results would be expected to be produced.

In the first case, since the individual foraminous portions of thebacking means are at least about three times as large in area as anindividual aperture of the apertured forming means, the bundling effectof fluid streams from a plurality of separate forming apertures isexerted within a single foraminous area, in which at the same time thosevery streams are being intermingled for passage through the backingmeans. In this situation, the turbulence in and above the foraminousportions of the backing means, as the various streams of rearrangingfluid are consolidated into a single confined stream so as to move outof the rearranging zone, would be expected to destroy completely anytendency towards producing discrete yarn-like bundles of closelyassociated and substantially parallel fiber segments within the areasoverlying the foraminous portions of the backing means.

In the second case, the streams of rearranging fluid that enter thefiber rearranging zone at spaced locations above the continuousimperforate portions of the backing means tend to produce yarn-likebundles of fiber segments to bridge those imperforate portions. Now theturbulence in the areas of the fibrous web above the foraminous portionsof the backing means works against this bundling effect not only bytending to prevent the formation of any discrete yarn-like bundles abovethe foraminous portions (as just described), but by opposing theformation of bundles over the imperforate portions of the backing meansas well. For the action of the fluid forces in an area of turbulence notonly tends to interentangle and consolidate the fiber segments as theyextend into the web areas on either side of the imperforate portions ofthe backing means which they bridge, but also tends to pull the fibersegments taut and spread them out in a flat array over the imperforateland areas of the backing means, and both these tendencies opposeseparation of the fiber segments into discrete closely packed yarn-likebundles to bridge the land areas of the backing means. This lattereffect is magnified by the fact that the fluid forces exerted in an areaof turbulence such as just referred to are markedly greater than thebundling forces applied within an aperture of the apertured formingmeans, since the area of each foraminous portion of the backing means isat least about three times as large as the area of each of theapertures.

Surprisingly, it has been found that the turbulence of the rearrangingfluid as it passes through the foraminous portions of the backing meansdoes not produce any of the undesirable results just described, eitherin the areas of the fibrous web above those foraminous portions or inthe areas above the imperforate portions therebetween. On the contrary,the method and apparatus of this invention successfully combine the twotypes of fluid rearranging forces to bring about satisfactory fiberrearrangement of two or more dissimilar types, and thus produce anattractive nonwoven fabric having a plurality of patterns, each of whichpatterns alternates and extends throughout the fabric.

FURTHER DESCRIPTION OF INVENTION shown and described fully in my US.Pat. No. 2,862,251, issued Dec. 2, 1958. Full particulars of the basicin-vention as disclosed in that patent are incorporated in thisapplication by reference, although some of those particulars arerepeated here. In addition, the specific feature peculiar to the methodand apparatus of the present invention which is the use of a fiberrearranging zone having spaced entry zones (for example, the aperturesof an apertured forming means) on one side, and continuous barrier zonesand discontinuous, foraminous fiber accumulating zones on the other side(for example, a backing means that is imperforate except fordiscontinuous foraminous portions), each entry zone having a width atits narrowest part equal to at least a specified number of times theaverage diameter of the fibers in the fibrous starting material, andeach fiber accumulating zone having an area at least a specified numberof times larger than the area of an entry zone is described in detail inthis application.

Starting Material The starting material used with the method orapparatus of this invention may be any of the standard fibrous webs suchas oriented card webs, isowebs, airlaid webs, or webs formed by liquiddeposition. The webs may be formed in a single layer, or by laminating aplurality of the webs together. The fibers in the web may be arranged ina random manner of may be more or less oriented as in a card web. Theindividual fibers may be relatively straight or slightly bent. Thefibers intersect at various angles to one another such that, generallyspeaking, the adjacent fibers come into contact only at the points wherethey cross. The fibers are capable of movement under forces applied byfluids such as water, air, etc.

To produce a fabric having the characteristic hand and drape of atextile fabric, the layer of starting material used with the method orapparatus of this invention may comprise natural fibers such as cotton,flax, etc., mineral fibers such as glass; artificial fibers such asviscose rayon, cellulose acetate, etc., or synthetic fibers such as thepolyamides, the polyesters, the acrylics, the polyolefins, etc., aloneor in combination with one another. The fibers used are those commonlyconsidered textile fibers; that is generally having a length from about4 inch to about 2 to 2% inches. Satisfactory products may be produced inaccordance with this invention from starting webs weighing betweengrains pe S 9l9ll9 lZQQiEEIELQ! squared??? or somewhat higher.

Apertures Forming Means In one form of the method of this invention, andin the apparatus of this invention, the fluid entry zones into the fiberrearranging zone are defined by an apertured forming means.

The apertured forming means used with the method and apparatus of thisinvention is solid throughout its area except for the forming aperturesdisposed longitudinally and transversely across the member. The formingapertures may have any desired shape, i.e., round, square, diamond,oblong, free form, etc.

The width at the narrowest part of each of the apertures of theapertured forming means must be large enough that streams of rearrangingfluid passing through those apertures will be effective to separategroups of fiber segments into yarn-like bundles spaced sufficiently farapart to permit reliable visual resolution. Without such resolution, anybundle of fiber segments produced would seem to the person viewing thefabric to fuse or merge together with other such bundles, with theresult that no clear pattern would be apparent in the fabric. To achievesuch resolution, the width of each aperture at its narrowest part shouldbe equal to at least about ten times, and preferably at least abouttwenty times, the average diameter of the fibers in the fibrous startingmaterial; i.e., at least 0.015 inch and preferable 0.020 inch.

The maximum dimensions of each aperture of the apertured forming meansare limited by the requirement mentioned below as to the ratio betweenthe areas of the forming apertures and the foraminous portions of thebacking means.

The land areas of the apertured forming means that lie between andinterconnect the forming apertures may be either narrow or broad incomparison to the forming apertures,as desired. Generally speaking, thenarrower the land areas are, the more tightly compacted will be theyarn-like bundles of closely associated and substantially parallel fibersegments that are formed beneath those land areas.

Backing Means Having Discontinuous Foraminous Portions As alreadyindicated, in one form of this invention the fibrous starting layer issupported on backing means having foraminous portions arranged in adiscontinuous pattern, and continuous imperforate portions that liebetween and interconnect the discontinuous foraminous portions toprovide barrier zones against the passage or rearranging fluid out ofthe fiber rearranging zone. For ease of visual resolution of thedifferent fiber patterns of the nonwoven fabric made by the practice ofthis invention, the width of each imperforate portion of the backingmeans at its narrowest part is equal to at least about the width of thenarrowest part of the aperture of the apertured forming means with whichthe backing means is used. The foramina of the foraminous portion of thebacking means are substantially smaller than the apertures of theapertured forming means.

The bridging of the imperforate portions of the backing means by alignedfiber segments referred to above that is produced by the practice ofthis invention is brought about by three factors good drainage of therearranging fluid from the fiber rearranging zone with no uncontrolledwashing away of fibers, the accumulation and retention of groups offiber segments at spaced points across the backing means, and thepulling taut of other fiber segments that extend between such groups andare anchored by them at a plurality of points along their lengths. 4

Good drainage is achieved by avoiding the use of too much rearrangingfluid and by employing discontinuous foraminous portions in the backingmeans that are large enough and not too widely spaced. As indicatedabove, the area of each of the discontinuous foraminous portions of thebacking means should be at least about three times, and preferably fourtimes, the area of an aperture of the apertured forming means. Theseforaminous portions should be closely enough spaced to each other thatthey occupy together at least about per cent, and preferably about 30per cent or even more, of the total area of the backing means.

Accumulation and retention of fiber segments at spaced points across thebacking means takes place when each foraminous portion of the backingmeans is large enough that a group of fibers can be accumulated andretained there, whether in the form of a group of fiber segmentsincluding only a single yarn-like bundle or a plurality of yarn-likebundles of fiber segments. This condition is automatically met in thepresent invention by the restrictions on the minimum dimension of eachaperture of the apertured forming means (i.e., an entry zone) incomparison to the average fiber diameter, and on the relative area ofeach foraminous portion of the backing means (i.e., a fiber accumulatingzone) in comparison to the area of a forming aperture. There is nopractical limit other than esthetic requirements on the maximum area ofeach foraminous portion of the backing means.

The pulling taut of fiber segments between adjacent groups in which theyare anchored is achieved by limiting the maximum spacing of theforaminousportions of the backing means. To establish two reliableanchor points for each individual fiber segment, the foraminous portionsof the backing means should be spaced from other such portionsimmediately adjacent thereto by no more than about A: the average lengthof the fibers being rearranged, and preferably no more than about 1/5 orl/6 the length of the fibers. In general, this means that with 1% inchesstaple length fibers, each pair of foraminous portions of the backingmeans should be spaced, at their closest points, no more than about 7%inch arart, and preferably no more than about A inch.

When the spacing referred to is about one to two times thewidth, at itsnarrowest part, of an aperture of the apertured forming means, thealigned fiber segments may take the form of yarn-like bundles extendingbetween the areas of the fabric lying above adjacent foraminous portionsof the backing means. When the spacing in question is about three ormore times the width of a forming aperture at its narrowest part, thealigned fiber segments ordinarily take the form of flat, ribbon-likegroups of segments.

In plan view, the discontinuous foraminous portions of the backing meansmay have any shape desired, i.e., circular, oval, diamond, square, etc.

The discontinuous foraminous portions may be flush with the imperforateportions of the backing means, or at a different elevation. If athree-dimensional effect is desired for the fiber grouping accumulatedat each foraminous portion of the backing means, the continuousimperforate portions of the backing means should lie above theforaminous portions by at least about 1/32 inch, or as much as l/ 16inch if desired. This difference in height must not be too great,however, if a pattern of yarn-like bundles of fiber segments (producedeither by the apertures of the apertured forming means or byprotuberances on the discontinuous foraminous portions of the backingmeans) is also desired.

Generally speaking, with a foraminous portion at a lower elevation, thelarger the area of the foraminous portion, the more pronounced will bethe threedimensional effect in the resulting fabric. Thethreedimensional effect also increases with increased flexibility in thefibers being arranged, since the more flexible a fiber is, the moreeasily it can conform to the lower elevation of the foraminousportionsof the backing means.

As already indicated above, when a fourth pattern of areas of low fiberdensity is desired in the fabric produced by use of the backing meansalready described in the method or apparatus of this invention, thediscontinuous foraminous portions of the backing means are provided witha plurality of protuberances and troughs alternating across theirsurface in both the longitudinal and transverse directions. Asillustrated in the drawings below, the tops of the protuberances riseabove the bottoms of the immediately adjacent troughs by a verticaldistance equal to at least about three times the average diameter of thefibers in the layer of fibrous starting material or about 0.005 inch.Preferably, the distance should be equal to about ten times the averagediameter of those fibers. The protuberances should not rise so far abovetheir immediately adjacent troughs as to disrupt formation of anypattern of areas of low fiber density present that corresponds to theapertures of the apertured forming means. The top of each protuberanceis spaced from the tops of the immediately adjacent protuberances by ahorizontal distance equal to at least about 30 times the averagediameter of the fibers of said fibrous starting material.

During use of the method or apparatus of this invention, the aperturedforming means and the backing means are spaced from each other toprovide a fiber rearranging zone in which fiber movement in directionsparallel to the backing means is permitted in response to applied fluidforces.

Rearranging Fluid The rearranging fluid for use with this invention ispreferably water of a similar liquid, but it may be other fluids such asa gas, as described in my US. Pat. No. 2,862,251.

If desired, a vacuum may be applied at the exit side of the fiberrearranging zone of this invention, to assist in moving the rearrangingfluid through the fibrous starting material and in rearranging thefibers of the material into a patterned nonwoven fabric. This feature ismost useful when the rearranging fluid is a liquid.

BRIED DESCRIPTION OF THE DRAWINGS The invention will be more fullydescribed in connection with the accompanying drawings, in which:

FIG. 1 is a diagrammatic showing in elevation of one type of apparatusthat can be employed in the present invention.

FIG. 2 is an enlarged diagrammatic plan view of a portion of a backingmeans that can be used in the apparatus of FIG. 1.

FIG. 3 is a cross sectional view taken along the line 3-3 of FIG. 2.

FIG. 4 is a further enlarged diagrammatic plan view of the element shownin FIG. 2, with the apertures of the apertured forming means used inconjunction therewith shown in dashed lines.

FIG. 5 is an enlarged fragmentary diagrammatic plan view of theforaminous portion of another backing means that can be used with theapparatus of FIG. 1, an aperture of the apertured forming means beingshown in dashed lines.

FIG. 6 is a cross sectional view taken along the line 6-6 of FIG. 5.

FIG. 7 is a cross sectional view taken along line 7-7 of FIGS. 5 and 6.

FIGS. 8 is a photomicrograph of a nonwoven fabric made in accordancewith the present invention, shown at an original enlargement of fivetimes.

FIG. 9 is a photomicrograph of another non-woven fabric made inaccordance with the present invention, shown at an original enlargementof five times.

FIG. 10 is an enlarged diagrammatic plan view of a portion of anotherbacking means.

FIG. 11 is a cross sectional view taken along the line 11-11 of FIG. 10.

FIG. 12 is a photomicrograph of another non-woven fabric made inaccordance with the present invention, shown at an original enlargementof five times.

FIG. 13 is a photomicrograph of the fabric of FIG. 12 from the oppositeside, showing a different but similar portion of the fabric, at anoriginal enlargement of five times.

FIG. 14 is a photomicrograph of another nonwoven fabric made inaccordance with the present invention, shown at an original enlargementof five times.

FIG. 15 is a photomicrograph of the fabric of FIG. 14 from the oppositeside, showing a different portion of the fabric, at an originalenlargement of five times.

FIG. 16 is an enlarged diagrammatic plan view of a portion of anotherbacking means.

FIG. 17 is a cross sectional view taken along the line l717 of FIG. 16.

FIG. 18 is a photomicrograph of another nonwoven fabric made inaccordance with the present invention, shown at an original enlargementof five times.

FIG. 19 is a photomicrograph of the fabric of FIG. 18 from the oppositeside, showing a similar portion of the fabric, at an originalenlargement of five times.

FIG. 20 is a photomicrograph of another nonwoven fabric made inaccordance with the present invention, shown at an original enlargementof five times.

FIG. 21 is a photomicrograph of the fabric of FIG. 20 from the oppositeside, showing the same portion of the fabric, at an original enlargementof five times.

FIG. 22 is a schematic drawing that represents a portion of the nonwovenfabric of FIGS. 20 and 21.

FIG. 23 is a schematic drawing that represents a further portion of thesame nonwoven fabric.

FIG. 24 is an enlarged diagrammatic showing of another fabric made inaccordance with this invention.

DETAILED DESCRIPTION OF SPECIFIC FORMS OF THE INVENTION FIG. 1 shows oneform of apparatus that may be used in accordance with the presentinvention. Full particulars of the basic apparatus of which. thisapparatus is a specific form, including methods of mounting, rotation,etc., are described in US. Pat. No. 2,862,251 issued Dec. 2, 1958, andare incorporated in the present application by reference and thus neednot be described in complete detail here. In view of this reference, theapparatus of FIG. 1 will be described in general terms insofar as itsessential elements are the same as in the patent just mentioned, and asalready explained above, the novel feature used to manufacture non-wovenfabrics in accordance with the present invention will be described inmore detail.

The apparatus of FIG. 1 includes a rotatable backing drum 15 suitablymounted on flanged guide wheels 17 and 18, which are mounted forrotation on shafts 25 and 26. The drum has foraminous portions 19uniformly spaced over its entire surface, with the remaining portions ofthe drum that lie between and interconnect the foraminous portionsconstituting imperforate land areas 20 Backing drum 15, as shown in FIG.2, has a discontinuous pattern of foraminous portions 19 and acontinuous pattern of imperforate portions 20 lying between andinterconnecting them. In FIG. 2, the foraminous portions are round andarranged such that four of them lie in a square pattern over the surfaceof drum 15. As already indicated above, the foraminous portions of thebacking member may have any shape desired. They may also be arranged inany discontinuous pattern over the backing member; i.e., they may bealigned longitudinally and/or transversely, staggered, etc.

FIG. 3 shows a cross section of the backing means of FIG. 2. As seeneach continuous imperforate portion 20 of backing means 15 has a curvedtop surface that rises slightly above the top surface of foraminousportions 19 of the backing means. Because of the curved top surface,central portion 21 rises above edge portions 22 of imperforate portion20 of the backing means. Extreme edge portions 23 are slightly rounded.

Outside the drum, a stationary manifold 27 to which a fluid is suppliedthrough conduit 28 extends along the full width of the drum. On one sideof the manifold is a series of nozzles 29 for directing the fluid towardthe drum.

About the greater portion of the periphery of the drum there ispositioned an apertured forming belt 30. Forming belt 30 is solidthroughout its area except for forming apertures 31 disposed across itssurface. As already indicated above, these forming apertures may haveany shape desired. They may also be arranged in any discontinuouspattern over the support member; i.e., they may be alignedlongitudinally and/or transversely staggered, etc., with continuous landareas 32 between them. In the apparatus of FIG. 1, forming apertures 31are circular in shape and are arranged such that four of them lie in asquare pattern over the surface of forming belt 30.

The diameter of circular apertures 31 is at least about ten times theaverage diameter of the fibers in the fibrous starting material. Withfibers of l k denier, for example, the diameter of apertures 31 is 0.015inch or larger.

Forming belt 30 passes about drum l and separates from the drum at guideroll 33, which rotates on shaft 34. The belt passes downwardly aroundguide roll 35, rotating on shaft 36, and then rearwardly over verticallyadjustable tensioning and tracking guide roll 37 rotating on shaft 38,and then around guide roll 39 on shaft 40. The member passes upwardlyand around guide roll 41 rotating on shaft 42, to be returned about theperiphery of the drum.

Backing drum l5 and apertured forming belt 30 provide a rearranging zonebetween them through which a fibrous starting material may move to berearranged, under the influence of applied fluid forces, into a nonwovenfabric having a plurality of patterns of fiber segments that extendthroughout its area.

Tension on forming belt 30 is controlled and adjusted by the tensioningand tracking guide roll. The guide rolls are positioned in slideablebrackets which are adjustable to assist in the maintenance of the propertension of the belt. The tension required will depend upon the weight ofthe fibrous web being treated and the amount of rearrangement andpatterning desired in the final product.

Backing drum rotates in the direction of the arrow shown, and aperturedforming belt 30 moves in the same direction at the same peripherallinear speed and within the indicated guide channels, so that bothlongitudinal and lateral translatory motion of the backing means, theapertured forming means, and the fibrous 5 layer with respect to eachother are avoided. The fibrous material 43 to be treated is fed betweenthe backing drum and apertured forming member 30 at point A," passesthrough a fiber rearranging zone where fluid rearranging forces areapplied to it, and is removed in its new, rearranged form as nonwovenfabric 44 between the backing drum and apertured forming belt at pointB.

As fibrous material 43 passes through the fiber rearranging zone, aliquid such as water is directed against the outer surface of aperturedforming belt 30 by nozzles 29 mounted outside the drum, the water passesthrough apertures 31 of forming means 30 into the layer of fibrousstarting material 43 to produce rearrangement of the fibers of the web,and the water thence passes through foraminous portions 19 of backingdrum l5.

Vacuum assist box 45 is located inside rotating drum 15 oppositemanifold 27 and nozzles 29. Vacuum box 45 has a slotted surface locatedclosely adjacent the inner cylindrical surface of drum 15, and throughwhich suction is caused to act upon the web. Suction thus appliedassists in the rearrangement of the fibers as the web material passesthrough the rearrangign zone. In addition, it serves to help dewater theweb and prevent flooding during fiber rearrangement. A drain pan 46 isprovided in order that water deflected by the v outside of aperturedforming belt 30 will be carried away from the machine.

In the apparatus of FIG. 1, the relative positioning of rotatablebacking drum l5 and apertured forming means 30 with respect to thefibrous layer 43 being rearranged is maintained through the rearrangingzone as explained above by guarding against either longitudinal orlateral translatory movement. This maintains the integrity of therearranged fabric as it is subjected to fluid forces from therearranging liquid.

FIG. 4 is a still further enlarged diagrammatic view of a portion ofbacking means 15 used in the apparatus of FIG. 1. Discontinuousforaminous portions 19 are circular in shape and are arranged in asquare pattern over the surface of the backing member. The remainder ofthe backing member is comprised of continuous imperforate portions 20.Circular forming apertures 31 of apertured forming means 30, alsoarranged in a square pattern, are shown in dashed lines. During use ofthe apparatus of FIG. 1, apertured forming means 30 and backing means 15are spaced from each other to provide a fiber rearranging zone.

The directions the streams of rearranging fluid projected throughapertures 31 of apertured forming means 30 take as they move into andthrough the fibrous web determine the type of forces applied to thefibers and in turn, the extent of rearrangement of the fibers. Since thedirections the streams of rearranging fluid take after they pass throughapertures 31 are determined by foraminous portions 19 and imperforateportions 20 of support member or backing means 15, it follows that thepatterns of these portions of the backing means help determine thepatterns of fiber arrangement, as well as the patterns of holes or otherareas of low fiber density, in the resultant fabric.

When backing means 15 and apertured forming means 30 are employed in themethod or apparatus of this invention as shown in FIG. 4, streams ofrearranging fluid passing through forming apertures 31 cause some of thefiber segments that are in registry with continuous imperforate portionsof backing means 15 to move into areas of fibrous layer 43 overlyingforaminous portions 19 of the backing means, to form groups of fibersegments there that include at least one yarnlike bundle of closelyassociated and substantially parallel fiber segments in each such area.At the same time, the streams of rearranging fluid move other fibersegments that are in registry with imperforate portions 20 intosubstantial alignment in positions bridging the continuous imperforateportions of the backing means from one discontinuous foraminous area 19to another.

This fiber rearrangement produces a first pattern of fiber segmensarranged in accordance with the pattern of arrangement of foraminousportions 19 of backing means 15, including at least one yarn-like bundleof closely associated and substantially parallel fiber segments in eacharea of the fibrous web that overlies one of the foraminous portions 19,and a second pattern of substantially aligned fiber segmentsinterconnecting the portions of the fabric in the first pattern. Thesecond pattern corresponds to the configuration of continuousimperforate portions 20 of backing means 15.

If the fibrous starting web 43 is not of too heavy a weight, a thirdpattern of rearranged fibers may be produced within the first patternjust described. In this type of fiber rearrangement, when fiber segmentsthat are in registry with imperforate portions 20 of backing means 15are moved into areas overlying foraminous portions 19 of the backingmeans, fiber segments in the resulting groups of fiber segments that arein registry both with foraminous portions 19 and with forming apertures31 are moved into areas underlying land areas 32 between apertures 31,and are positioned therein a plurality of yarn-like bundles of closelyassociated and substantially parallel fiber segments. The third patternof yarn-like bundles of fiber segments thus arranged within the firstpattern of fibers corresponds with the pattern of land areas 32 ofapertured forming means 30.

If the fibrous web being rearranged is too heavy, the fibers that aremoved by the streams of rearranging fluid from areas of the fibrousstarting material overlying imperforate portions 20 of backing means 15into areas overlying foraminous portions 19 of the backing means willpack the latter areas so full of fibers that no areas of low fiberdensity, much less any apertures or holes substantially free of fibers,can be produced there. In such a situation, any areas of low fiberdensity that tend to appear during the fluid rearrangement process willbe masked out by the heavy accumulating of fibers. If imperforateportions 20 rise above foraminous portions 19, or in other words theforaminous portions provide depressed areas on backing means 15, alarger number of fibers from a heavier starting web can be accommodatedin those depressed foraminous areas without masking or blocking out theareas of low fiber density that tend to appear between the yarn-likebundles of fiber segments that are formed by the fluid rearrangingforces.

Above about 400 grains per sq. yd. with fibers of l A denier, mats ofrandomly oriented, helter-skelter fiber segments are ordinarily includedin the first pattern of fiber segments in the nonwoven fabric resultingfrom the practice of this invention.

With imperforate portions 20 raised only slightly above the foraminousportions of the backing means, it has been found that satisfactoryformation of yarnlike bundles of fiber segments in the third patterndescribed just above, with areas of low fiber density clearly delineatedbetween the yarn-like bundles, can be achieved with a fibrous startingmaterial made up of fibers of 1 A denier that has a web weight up toabout 600 grains per square yard, or somewhat heavier for higher denierfibers. Between about 600 and about 800 grains per square yard, withfibers of l 7% denier, a full pattern of yarn-like bundles is formedwith somewhat less clarity. With a web weight of from about 800 to 1200grains per square yard, it is ordinarily not possible to form a fullthird pattern of fiber segments in this manner, but individual yarn-likebundles may be formed in association with the other fiber segments thatlie in randomly oriented, helter-skelter relationship to each other inthe first pattern of the fabric. With a web weight of 1200 grains persquare yard or more, even in dividual yarn-like bundles are ordinarilynot produced. The web weights in question may be somewhat heavier, thehigher the continuous imperforate portions rise above the discontinuousforaminous portions of the backing means.

FIG. 5 gives an enlarged fragmentary diagrammatic plan view of theforaminous portion 50 of another backing means that can be used with theapparatus of FIG. 1. Foraminous portion 50 of the backing means for usein this invention is formed of coarse woven screen, preferably metal. Inthe embodiment shown, wires 51 running vertically in FIG. 5 arestraight, while wires 52 running horizontally in that figure weavealternately over and under wires 51. Protuberances 53 are presentthroughout foraminous portion 50 as the topmost part of each knee of agiven strand 52 of the screen that is formed as the strand weaves overand under the strands 51 that lie perpendicular to it.

As a given strand 52 slants downward to pass under a strand 51perpendicular to it, it crosses two other strands 52 disposed on eitherside of it, as those strands slant upward to pass over the sameperpendicular strand that the given strand will pass under. Each seriesof such crossing points 54 forms a trough, such as trough 55 formed bycrossing points 54 in FIGS. 5 and 6, that lies between adjacentprotuberances 53. The effective shape of troughs 55, as can be best seenin FIG. 6 (which shows a cross section of element 50 of which a planview is given in FIG. 5), is substantially an inverted triangle.

A series of slightly deeper troughs 56 is formed between adjacentprotuberances 53 but extending at right angles to troughs 55. As bestseen in FIG. 7, the bottom of each trough 56 is formed by portions ofstraight strands 51, with successive protuberances 53 on each side ofthe trough forming the tops of the trough. As seen in FIG. 7, theeffective shape of troughs 56 may be characterized as a shallow U-shape.

As shown in FIG. 5, a plurality of troughs 55 and a plurality ofprotuberances 53 alternate in one direction across the surface offoraminous portion 50 of the backing means. FIG. 5 also shows that aplurality of troughs 56 and a plurality of protuberances 53 alternate ina direction perpendicular to troughs 55. Hence a plurality of troughsand a plurality of protuberances alternate in both the longitudinal andtransverse directions across the surface of foraminous portion 50 of thebacking means.

Use in the method or apparatus of this invention of a backing meanshaving foraminous portions such as element 50 shown in FIGS. through 7,with a starting web that is not of too heavy a weight, produces a fourthpattern of rearranged fibers within the third pattern already mentionedabove. This fourth pattern is made up of yarn-like bundles of fibersegments that have been positioned in troughs 55 and troughs 56 on thesurface of foraminous portions 50 of the backing means.

To produce satisfactory rearrangement of fibers into yarn-like bundlesof closely associated and substantially parallel fiber segmentspositioned in troughs 55 and in troughs 56, the vertical distancebetween the tops of protuberances 53 and the bottoms of the immediatelyadjacent troughs should be at least about three times, generally no morethan about to times, and preferably about five to about ten times, theaverage diameter of the fibers in the layer of fibrous startingmaterial. For troughs 55, this distance is the vertical distanceindicated in FIG. 6 by the pair of dashed lines that pass, respectively,through the tops of protuberances 53 and the crossing points 54 thatdefine the troughs. The vertical distance from the bottom of each trough56 to the tops of protuberances 53, on the other hand, is somewhatlarger, being shown by FIGS. 6 and 7 to be equal to the diameter of astrand 52.

The relative position of a forming aperture 31 and protuberances 53 offoraminous portion 50 of the backing means in one form of the method andapparatus of this invention is shown in dashed lines in FIG. 5. As isseen, aperture 3, in both the longitudinal and transverse directions,has a width somewhat larger than two times the horizontal distancebetween the tops of immediately adjacent protuberances 53 on foraminousmember 50, and spans two such protuberances measured in both thelongitudinal and transverse directions.

During use of this invention, apertured forming means and the backingmeans of which element is a part are spaced to provide a fiberrearranging zone.

Portions of the streams of rearranging fluid that pass through formingapertures 31 and the fibrous web pass directly through openings 57between adjacent wires of woven screen 50. Other portions of the streamsof rearranging fluid that have passed through apertures 31 strike thewires of woven screen 50, at protuberances 53 or at other portions ofthe wire, and are deflected sidewise before they pass out of therearranging zone through openings 57.

The streams of rearranging fluid just described move some of the fibersegments that are in registry with apertures 31 and overlie foraminousportions 50 of the backing means into surrounding areas of the fibrouslayer, positioning the fiber segments there in yarn-like bundles ofclosely associated and substantially parallel fiber segments, to defineholes or other areas of low fiber density in a pattern corresponding tothe pattern of apertures 31. This pattern of yarn-like bundles isreferred to above as the third pattern of fiber segments in thenon-woven fabric made in accordance with this invention. At the sametime, the fluid rearranging forces move other fiber segments that are inregistry with forming apertures 31 and overlie foraminous portions'50into troughs 55 and troughs 56 in element 50,

means 30) at their closest spacing is at least about three times thewidth of an entry zone at its narrowest part. Spacing that is this greattends to interfere with, and destory, the bundling effect of therearranging fluid that enters the fiber rearranging zone in discretestreams through the spaced entry zones.

With some forms of the invention, the aligned interconnecting fibersegments extending between the groups of fiber segments of the firstpattern are further rearranged by deflected streams of rearranging fluidinto yarn-like bundles of closely associated and substantially parallelfiber segments. These yarn-like bundles may be parallel with all theother similar bundle lying between and interconnecting a given pair ofgroups of fiber segments in the first pattern, or they may be organizedinto a latticework of yarn-like bundles extending between that pair ofgroups of fiber segments. In these forms of the invention, the spacingbetween immediately adjacent fluid entry zones is no greater than abouttwo times the width of an entry zone at its narrowest part. With spacingno greater than this, the discrete streams of rearranging fluid enteringseparate fluid entry zones are effective to produce the described fiberbundling in the groups of aligned fibers that interconnect portions ofthe fabric in the first pattern.

The rearranged web or fabric produced by the practice of this inventionmay be treated with an adhesive, dye or other impregnating, printing, orcoating material in a conventional manner. For example, to strengthenthe rearranged web, any suitable adhesive bonding materials or bindersmay be included in an aqueous or non-aqueous medium employed as therearranging fluid. Or an adhesive binder may, if desired, be printed onthe rearranged web to provide the necessary fabric strength.Thermoplastic binders may, if desired, be applied to the rearranged webin powder form before, during or after rearrangement, and then fused tobond the fibers.

The optimum binder content for a given fabric according to thisinvention depends upon a number of factors, including the nature of thebinder material, the size and shape of the binder members and theirarrangement in the fabric, the nature and length of the fibers, totalfiber weight, and the like. In some instances, because of the strengthof the fibers used or the tightness of their interentanglement in therearranged web or fabric, or both, no binder at all need be employed toprovide a usable fabric.

The following are illustrative examples of use of the method andapparatus of this invention to produce patterned nonwoven fabrics:

EXAMPLE 1 In apparatus as illustrated in FIG. I, a web 43 of containsviscose rayon fibers approximately 1 9/16 n e 2f ,34 in he denier- Theapertured forming belt 30 used in this example has about 1 65substantially round holes per square inch, each approximately 0.045 inchin diameter. The width of each of these apertures 31 is thus equal toabout 30 times the 0.0015 inch average diameter of the 1 h denier fibersof the fibrous starting material. The holes are arranged in a diamondpattern over the forming means. Each aperture 31 is spaced approximately0.040 inch in the diagonal direction from the immediately adjacentaperture on the forming belt.

Cylindrical backing drum in the apparatus of this example is constructedof a smooth surfaced metal having foraminous circular portionsdistributed across its surface in a diamond pattern.

Foraminous portions 19 of backing drum 15 are comprised of a woven nylonscreen of approximately 28 X 34 mesh or substantially 952 openings persquare inch. Each of these foraminous portions 19 has a diameter ofapproximately 74; inch, with a space of approximately Va inch from eachportion 19 to the nearest other portion 19 in a diagonal direction.

Discontinuous foraminous portions 19 are interconnected by thecontinuous metal portions of the drum. These continuous imperforateportions 20, in the area between each pair of immediately adjacentforaminous portions 19, have a central portion 21 that rises 0.012 inchabove the plane of the top surface of discontinuous foraminous portions19 of the backing means, and edge portions 22 that rise about 0.010 inchabove the plane described.

Because of the indicated spacing of approximately 4; inch betweenforaminous portion 19 of backing drum 15, it follows that the width ofeach imperforate portion at its narrowest part is about three times thewidth of an aperture 31 at its narrowest part.

Except for the diamond patterns of apertures 31 and foraminous portions19, apertured forming means and backing means 15 are disposed generallyas shown in FIG. 4.

Water is projected from nozzles 29 through apertures 31 in aperturedforming means 30, and thence through fibrous web 43 and foraminousportions 19 of backing drum 15 into vacuum assist box 45.

After a given portion of fibrous web 43 passes through the rearrangingzone, in which streams of water are directed against it as justdescribed, the rotation (in the counterclockwise direction as seen inFIG. 1) of the sandwich comprised of aperture forming belt 30, therearranged nonwoven fabric 43, and backing drum 15 brings the rearrangedfabric to takeoff zone B." There the rearranged nonwoven fabric leavesthe apparatus.

With the conditions indicated, good fiber rearrangement and bundling areobtained, and an excellent nonwoven fabric such as shown in thephotomicrograph of FIG. 8, which has a plurality of patterns thatalternate and extend throughout the fabric, is produced.

Nonwoven fabric 60 of FIG. 8 contains a first pattern of fiber segments61 arranged in accordance with the pattern of arrangement ofdiscontinuous foraminous portions 19 of backing drum 15. The nonwovenfabric also contains a second pattern of substantially aligned fibersegments 62 interconnecting the portions of ribbon-like groups of thefabric in the first pattern 61. This second pattern corresponds to theconfiguration of continuous imperforate portions 20 of backing drum 15.

The fabric also contains a third pattern of yam-like bundles of fibersegments 63. Each of these yarn-like bundles is formed of closelyassociated and substantially parallel fiber segments. This third patternof yarnlike bundles of fiber segments 63 is arranged within the firstpattern of fibers 61 in accordance with the pattern of land areas 32 ofapertured forming belt 30. Yarn-like bundles 63 define within firstpattern 61 a pattern of areas of low fiber density 64 arranged inaccordance with the pattern of apertures 31 in apertured forming means30.

Each group of fiber segments 61 appears from FIG. 8 to be approximately25 times the size of each area of low fiber density 64, or a little bitlarger. This is consistent with the relative size of foraminous portions19 of backing drum l5 and apertures 31 of apertured forming belt 30 thatare included in the apparatus with which the fabric of FIG. 8 was made.Each foraminous portion 19 has a diameter of approximately inch, whichgives it an area of about 0.197 square inches, and each aperture 31 ofapertured forming belt 30 has a diameter of about 0.045 inch, whichgives it an area of 0.0064 square inches. In other words, the area ofeach foraminous portion 19 of backing drum 15 is about 30 times the areaof each aperture 31 of apertured forming belt 30.

EXAMPLE 2 FIG. 9 is a photomicrograph of another non-woven fabric madein accordance with the present invention by use of apparatus similar tothat described in Example 1, but with a starting web of fibrous materialof the type commonly called an isotropic web. The starting material hasa web weight of about 350 grains per square yard, and web strength ismeasured at substantially the same magnitude in every directionthroughout the web.

The fabric of FIG. 9 is generally similar to the fabric of Example 1.The respective patterns of fiber segments, as well as areas of low fiberdensity, that extend throughout the nonwoven fabric of FIG. 9 areindicated by the same designators in that figure as are used indescribing the nonwoven fabric of FIG. 8.

In the fabric of FIG. 9, each group of fiber segments 61 appears to beapproximately 25 times the size of each area of low fiber density 64, ora little larger. This is consistent, as was true of the fabric of FIG.8, with the relative size of foraminous portions 19 of backing drum l5and apertures 31 of apertured forming belt 30 that are included in theapparatus with which this fabric was made.

EXAMPLE 3 In apparatus as illustrated in FIG. 1, a web 43 of looselyassembled fibers, such as may be obtained by carding, is fed betweenapertured forming means 30 and backing means 15. The web weight is about320 grains per square yard, and its fiber orientation ratioapproximately 7 to 1 in the direction of travel. The web

1. A method of producing a patterned nonwoven fabric having a pluralityof patterns of groups of fiber segments that alternate and extendthroughout said fabric, from a layer of fibrous starting material whoseindividual fibers are in mechanical engagement with one another but arecapable of movement under applied fluid forces, which comprises:positioning said layer of fibrous starting material in a fiberrearranging zone, in which fiber movement in directions parallel to theplane of said fibrous material is permitted in response to applied fluidforces, that is defined on one side by forming means having aperturesspaced longitudinally and transversely with land areas therebetween, andon the other side by backing means that has foraminous portions arrangedin a discontinuous pattern with the foramina therein smaller than saidforming apertures and continuous imperforate portions lying between andinterconnecting said discontinuous foraminous portions, the width ofeach of said apertures at its narrowest part being equal to at leastabout ten times the average diameter of the fibers of the fibrousstarting material, the area of each of said discontinuous foraminousportions of the backing means being at least about three times the areaof an aperture of said apertured forming means, and the width of each ofsaid continuous imperforate portions of the backing means at itsnarrowest part being equal to at least about the width of one of saidforming apertures at its narrowest part; and projecting streams of fluidthrough said apertures and then against said fibrous layer to passtherethrough, some of said fluid streams thereafter striking saidcontinuous imperforate portions of the backing means and being deflectedthereby in sidewise directions, and all of said fluid streams passingthrough and beyond said foraminous portions of the backing means, tomove some of the fiber segments that are in registry with saidimperforate portions of the backing means into areas of said fibrouslayer overlying said foraminous portions of the backing means,positioning fiber segments thus moved with other fiber segments in eachof said last mentioned areas in at least one yarn-like bundle of closelyassociated and substantially parallel fiber segments in a locationtherein underlying said land areas of the apertured forming means, whilemoving others of said fiber segments that are in registry with saidimperforate portions into substantial alignment and in bridgingpositions extending between said discontinuous foraminous portions ofthe backing means, thereby forming a nonwoven fabric having a firstpattern of fiber segments arranged in accordance with the pattern ofarrangement of said discontinuous foraminous portions of the backingmeans, said first pattern including at least one of said yarn-likebundles of fiber segments in each of the areas of the fabric overlyingsaid foraminous portions, and a second pattern of substantially alignedfiber segments interconnecting the portions of the fabric in said firstpattern, said second pattern corresponding to the configuration of saidcontinuous imperforate portions of the backing means.
 2. The method ofclaim 1 in which each of said foraminous portions of the backing meanshas a plurality of protuberances and troughs alternating across thesurface thereof in both the longitudinal and transverse directions, thetops of said protuberances rising above the bottoms of the immediatelyadjacent troughs by a vertical distance equal to at least about threetimes the average diameter of the fibers in said layer of fibrousstarting material, the horizontal distance between the tops ofimmediately adjacent protuberances on said backing means being of aboutthe same general magnitude as the distance between the centers of saidapertures in the apertured forming means, and in which said streams ofliquid move fiber segments that are in registry with said apertuRes inthe apertured forming means and ovelie said foraminous portions of thebacking means into surrounding areas of said fibrous layer to positionsaid fiber segments there in yarn-like bundles of closely associated andsubstantially parallel fiber segments, and move other fiber segmentsthat are in registry with said forming apertures and overlie saidforaminous portions into said troughs in the backing means to positionsaid fiber segments there in yarn-like bundles of closely associated andsubstantially parallel fiber segments, to form a nonwoven fabric havingfirst, second, and third patterns of fiber segments as there defined,with a plurality of areas of low fiber density within said first patternof fiber segments, and a fourth pattern of yarn-like bundles of fibersegments positioned in said troughs to define a plurality of other areasof low fiber density within said first mentioned areas of low fiberdensity.
 3. Apparatus for producing a patterned nonwoven fabric having aplurality of patterns of fiber segments that alternate and extendthroughout said fabric, from a layer of fibrous starting material whoseindividual fibers are in mechanical engagement with one another but arecapable of movement under applied fluid forces, which comprises: backingmeans having portions that are foraminous and portions that areimperforate, at least 20 per cent of the total area of the backing meansbeing foraminous and the remainder being imperforate, said foraminousportions being arranged in a discontinuous pattern and the remainder ofsaid backing means being imperforate and lying between andinterconnecting said foraminous portions; apertured forming means spacedfrom said backing means to provide a zone in which fiber movement indirections parallel to said backing means is permitted in response toapplied fluid forces, the apertures in said forming means beinglongitudinally and transversely spaced with land areas therebetween, thewidth of each of said apertures at its narrowest part being at last0.015 inch, the width of each of said continuous imperforate portionsbeing equal at its narrowest part to at least about the width of one ofsaid apertures at its narrowest part, the area of each of saidforaminous portions of the backing means being at least about threetimes the area of an aperture of said apertured forming means; means formoving said backing means and apertured forming means, with a layer offibrous starting material positioned therebetween, through a rearrangingzone without any translatory motion between said two means and thefibrous layer; and means for projecting streams of fluid through saidapertures in the apertured forming means, and then against said fibrouslayer to pass therethrough, some of said fluid streams thereafterstriking said imperforate portions of the backing means and beingdeflected thereby in sidewise directions, and all of said fluid streamspassing through and beyond said foraminous portions of the backingmeans.
 4. The apparatus of claim 3 in which each of said foraminousportions of the backing means has a plurality of protuberances andtroughs alternating across the surface thereof in both the longitudinaland transverse directions, the tops of said protuberances rising abovethe bottoms of the immediately adjacent troughs by a vertical distanceequal to at least 0.005 inch, and the horizontal distance between thetops of immediately adjacent protuberances on said backing means are ofabout the same general magnitude as the distance between the centers ofsaid apertures in the apertured forming means.